Ultrasonic surgical instrument with blade cleaning feature

ABSTRACT

A surgical instrument includes a shaft assembly, an ultrasonic blade, and a cleaning device. The shaft assembly includes a first tube and an acoustic waveguide. The first tube has a first inner diameter and a distal end. The waveguide has a first outer diameter. The waveguide extends within the first tube. The first outer diameter of the acoustic waveguide and the first inner diameter of the first tube together define a gap. The ultrasonic blade extends distally from the distal end of the first tube. The acoustic waveguide is configured to communicate ultrasonic energy to the ultrasonic blade. The cleaning device is configured to actuate within the gap to thereby clean at least a portion of the shaft assembly and/or at least a portion of the ultrasonic blade.

BACKGROUND

A variety of surgical instruments include an end effector having a bladeelement that vibrates at ultrasonic frequencies to cut and/or sealtissue (e.g., by denaturing proteins in tissue cells). These instrumentsinclude one or more piezoelectric elements that convert electrical powerinto ultrasonic vibrations, which are communicated along an acousticwaveguide to the blade element. The precision of cutting and coagulationmay be controlled by the operator's technique and adjusting the powerlevel, blade edge angle, tissue traction, and blade pressure. Someinstruments have a clamp arm and clamp pad for grasping tissue with theblade element.

Examples of ultrasonic surgical instruments include the HARMONIC ACE®Ultrasonic Shears, the HARMONIC WAVE® Ultrasonic Shears, the HARMONICFOCUS® Ultrasonic Shears, and the HARMONIC SYNERGY® Ultrasonic Blades,all by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio. Further examplesof such devices and related concepts are disclosed in U.S. Pat. No.5,322,055, entitled “Clamp Coagulator/Cutting System for UltrasonicSurgical Instruments,” issued Jun. 21, 1994, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 5,873,873, entitled“Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Mechanism,”issued Feb. 23, 1999, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,980,510, entitled “Ultrasonic ClampCoagulator Apparatus Having Improved Clamp Arm Pivot Mount,” issued Nov.9, 1999, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,283,981, entitled “Method of Balancing AsymmetricUltrasonic Surgical Blades,” issued Sep. 4, 2001, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,309,400,entitled “Curved Ultrasonic Blade having a Trapezoidal Cross Section,”issued Oct. 30, 2001, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 6,325,811, entitled “Blades withFunctional Balance Asymmetries for use with Ultrasonic SurgicalInstruments,” issued Dec. 4, 2001, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 6,423,082, entitled“Ultrasonic Surgical Blade with Improved Cutting and CoagulationFeatures,” issued Jul. 23, 2002, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 6,773,444, entitled “Blades withFunctional Balance Asymmetries for Use with Ultrasonic SurgicalInstruments,” issued Aug. 10, 2004, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 6,783,524, entitled“Robotic Surgical Tool with Ultrasound Cauterizing and CuttingInstrument,” issued Aug. 31, 2004, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,057,498, entitled“Ultrasonic Surgical Instrument Blades,” issued Nov. 15, 2011, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,461,744, entitled “Rotating Transducer Mount for Ultrasonic SurgicalInstruments,” issued Jun. 11, 2013, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,591,536, entitled“Ultrasonic Surgical Instrument Blades,” issued Nov. 26, 2013, thedisclosure of which is incorporated by reference herein; and U.S. Pat.No. 8,623,027, entitled “Ergonomic Surgical Instruments,” issued Jan. 7,2014, the disclosure of which is incorporated by reference herein.

Still further examples of ultrasonic surgical instruments are disclosedin U.S. Pub. No. 2006/0079874, entitled “Clamp pad for Use with anUltrasonic Surgical Instrument,” published Apr. 13, 2006, now abandoned,the disclosure of which is incorporated by reference herein; U.S. Pub.No. 2007/0191713, entitled “Ultrasonic Device for Cutting andCoagulating,” published Aug. 16, 2007, now abandoned, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2007/0282333,entitled “Ultrasonic Waveguide and Blade,” published Dec. 6, 2007, nowabandoned, the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2008/0200940, entitled “Ultrasonic Device for Cutting andCoagulating,” published Aug. 21, 2008, now abandoned, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2008/0234710,entitled “Ultrasonic Surgical Instruments,” published Sep. 25, 2008,issued as U.S. Pat. No. 8,911,460 on Dec. 16, 2014, the disclosure ofwhich is incorporated by reference herein; and U.S. Pub. No.2010/0069940, entitled “Ultrasonic Device for Fingertip Control,”published Mar. 18, 2010, issued as U.S. Pat. No. 9,023,071 on May 5,2015, the disclosure of which is incorporated by reference herein.

Some ultrasonic surgical instruments may include a cordless transducersuch as that disclosed in U.S. Pub. No. 2012/0112687, entitled “RechargeSystem for Medical Devices,” published May 10, 2012, issued as U.S. Pat.No. 9,381,058 on Jul. 5, 2016, the disclosure of which is incorporatedby reference herein; U.S. Pub. No. 2012/0116265, entitled “SurgicalInstrument with Charging Devices,” published May 10, 2012, nowabandoned, the disclosure of which is incorporated by reference herein;and/or U.S. Pat. App. No. 61/410,603, filed Nov. 5, 2010, entitled“Energy-Based Surgical Instruments,” the disclosure of which isincorporated by reference herein.

Additionally, some ultrasonic surgical instruments may include anarticulating shaft section. Examples of such ultrasonic surgicalinstruments are disclosed in U.S. Pub. No. 2014/0005701, published Jan.2, 2014, issued as U.S. Pub. No. 9,393,037 on Jul. 19, 2016, entitled“Surgical Instruments with Articulating Shafts,” the disclosure of whichis incorporated by reference herein; and U.S. Pub. No. 2014/0114334,published Apr. 24, 2014, issued as U.S. Pub. No. 9,095,367 on Aug. 4,2015, entitled “Flexible Harmonic Waveguides/Blades for SurgicalInstruments,” the disclosure of which is incorporated by referenceherein.

While several surgical instruments and systems have been made and used,it is believed that no one prior to the inventors has made or used theinvention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a side elevational view of an exemplary ultrasonicsurgical instrument;

FIG. 2 depicts a perspective view of an end effector and shaft assemblyof the instrument of FIG. 1, in an open configuration;

FIG. 3A depicts a side elevational view of the end effector and shaftassembly of FIG. 2, in the open configuration;

FIG. 3B depicts a side elevational view of the end effector and shaftassembly of FIG. 2, in a closed configuration;

FIG. 4 depicts a side cross-sectional view of the end effector and shaftassembly of FIG. 2, in the open configuration;

FIG. 5 depicts a perspective view of an exemplary cleaning device thatmay be used to clean the end effector and shaft assembly of FIG. 2;

FIG. 6 depicts an exploded perspective view of the cleaning device ofFIG. 5;

FIG. 7 depicts a side cross-sectional view of the cleaning device ofFIG. 5;

FIG. 8 depicts a side cross-sectional view of the cleaning device ofFIG. 5, where the cleaning device is connected to a simple luer fittingand a fluid source;

FIG. 9A depicts a side cross-sectional view of the cleaning device ofFIG. 5 separated from the end effector and shaft assembly of FIG. 2,with the end effector in the open configuration;

FIG. 9B depicts a side cross-sectional view of the cleaning device ofFIG. 5 inserted within the end effector and shaft assembly of FIG. 2,with the end effector in the open configuration;

FIG. 10A depicts a perspective view of an exemplary disposable assemblythat may be incorporated into the ultrasonic instrument of FIG. 1, withthree cleaning brushes of FIG. 5 removed from the disposable assembly;

FIG. 10B depicts a perspective view of the disposable assembly of FIG.10A, with the three cleaning brushes housed within the disposableassembly;

FIG. 11 depicts a perspective view of an alternative cleaning devicethat may be used to clean the end effector and shaft assembly of FIG. 2;

FIG. 12 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and shaft assembly ofFIG. 2;

FIG. 13 depicts a front elevational view of the cleaning device of FIG.12;

FIG. 14 depicts an exploded perspective view of the cleaning device ofFIG. 12;

FIG. 15 depicts a perspective view of the cleaning device of FIG. 12,with a bristle section omitted;

FIG. 16 depicts a perspective view of the cleaning device of FIG. 12,with the bristle section included;

FIG. 17 depicts a perspective view of the cleaning device of FIG. 12,with the bristle section shown in transparency for further detail;

FIG. 18 depicts a cross-sectional side view of the proximal end of thecleaning device of FIG. 12;

FIG. 19 depicts a perspective view of a portion of another alternativecleaning device that may be used to clean the end effector and shaftassembly of FIG. 2;

FIG. 20 depicts perspective view of a portion of another alternativecleaning device that may be used to clean the end effector and shaftassembly of FIG. 2, with a bristle section omitted;

FIG. 21 depicts a perspective view of the cleaning device of FIG. 20,with the bristle section included;

FIG. 22 depicts a perspective cross-sectional view of the cleaningdevice of FIG. 20;

FIG. 23 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and shaft assembly ofFIG. 2;

FIG. 24 depicts a cross-sectional view of the cleaning device of FIG.23, taken along line 24-24 of FIG. 23;

FIG. 25A depicts a perspective view of the cleaning device of FIG. 23,with the bristle section omitted and a slidable sleeve in anon-retaining position;

FIG. 25B depicts a perspective view of the cleaning device of FIG. 23,with the bristle section included and the slidable sleeve in thenon-retaining position;

FIG. 25C depicts a perspective view of the cleaning device of FIG. 23,with the bristle section included and the slidable sleeve in a retainingposition;

FIG. 26 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and shaft assembly ofFIG. 2, with a bristle section omitted;

FIG. 27 depicts a side elevational view of the cleaning device of FIG.26, with the bristle section included;

FIG. 28 depicts a cross-sectional view of the cleaning device of FIG.26, with the bristle section included, taken along line 28-28 of FIG.27;

FIG. 29 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and the shaft assemblyof FIG. 2, with a sleeve is in the unlocked position;

FIG. 30 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and the shaft assemblyof FIG. 2;

FIG. 31 depicts a perspective view of another alternative cleaningdevice that may be used to clean the end effector and the shaft assemblyof FIG. 2;

FIG. 32 depicts a perspective view of an another alternative cleaningdevice that may be used to clean the end effector and the shaft assemblyof FIG. 2;

FIG. 33 depicts a perspective cross-sectional view of the cleaningdevice of FIG. 32;

FIG. 34 depicts a side cross-sectional view of the cleaning device ofFIG. 32;

FIG. 35A depicts a side cross-sectional view of an alternative shaftassembly and alternative end effector that may be incorporated into theinstrument of FIG. 1, where the shaft assembly includes a slidablyattached cleaning device, where the slidably attached cleaning device isin a first position;

FIG. 35B depicts a side cross-sectional view of the shaft assembly andend effector of FIG. 35A, where the slidably attached cleaning device isin a second position;

FIG. 36 depicts a top plan view of the shaft assembly and end effectorof FIG. 35A;

FIG. 37 depicts a side elevational view of another alternative shaftassembly and alternative end effector that may be incorporated in theinstrument of FIG. 1, where the shaft assembly includes a cleaningdevice that is slidable and rotatable;

FIG. 38 depicts a perspective view of the shaft assembly and endeffector of FIG. 37;

FIG. 39 depicts a front elevational view of a slidable cleaning devicethat may be attached to the end effector and the shaft assembly of FIG.2;

FIG. 40 depicts a side elevational view of the slidable cleaning deviceof FIG. 39;

FIG. 41 depicts a perspective view of the slidable cleaning device ofFIG. 39;

FIG. 42A depicts a cross-sectional side view of the slidable cleaningdevice of FIG. 39 attached to the end effector and the shaft assembly ofFIG. 2, where the end effector and the shaft assembly are in the openconfiguration;

FIG. 42B depicts a cross-sectional side view of the slidable cleaningdevice of FIG. 39 attached to the end effector and the shaft assembly ofFIG. 2, where the end effector and the shaft assembly are in the closedconfiguration;

FIG. 43 depicts a perspective view of another cleaning device attachedto an outer tube of the shaft assembly of FIG. 2;

FIG. 44 depicts a perspective view of the cleaning device of FIG. 43attached to the shaft assembly of FIG. 2, where the end effector andshaft assembly of FIG. 2 are in the open configuration;

FIG. 45A depicts cross-sectional side view of an alternative shaftassembly and end effector that may be incorporated into the instrumentof FIG. 1, where a waveguide of the shaft assembly is in a first,proximal position;

FIG. 45B depicts a cross-sectional side view of the shaft assembly andend effector of FIG. 45A, where the waveguide of the shaft assembly isin a second, distal position;

FIG. 46 depicts a cross-sectional view of the shaft assembly and endeffector of FIG. 45A, taken along line 46-46 of FIG. 45A, with a firstalternative embodiment of a cleaning feature; and

FIG. 47 depicts a cross-section view of the shaft assembly and the endeffector of FIG. 45A, taken along line 46-46 of FIG. 45A, with a secondalternative embodiment of the cleaning feature.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

For clarity of disclosure, the terms “proximal” and “distal” are definedherein relative to a human or robotic operator of the surgicalinstrument. The term “proximal” refers the position of an element closerto the human or robotic operator of the surgical instrument and furtheraway from the surgical end effector of the surgical instrument. The term“distal” refers to the position of an element closer to the surgical endeffector of the surgical instrument and further away from the human orrobotic operator of the surgical instrument.

I. Overview of Exemplary Ultrasonic Surgical Instrument

FIGS. 1-3 show an exemplary ultrasonic surgical instrument (10) that isconfigured to be used in minimally invasive surgical procedures (e.g.,via a trocar or other small diameter access port, etc.). As will bedescribed in greater detail below, instrument (10) is operable to cuttissue and seal or weld tissue (e.g., a blood vessel, etc.)substantially simultaneously. Instrument (10) of this example comprisesa disposable assembly (100) and a reusable assembly (200). The distalportion of reusable assembly (200) is configured to removably receivethe proximal portion of disposable assembly (100) to form instrument(10).

In an exemplary use, assemblies (100, 200) are coupled together to forminstrument (10) before a surgical procedure, the assembled instrument(10) is used to perform the surgical procedure, and then assemblies(100, 200) are decoupled from each other for further processing. In someinstances, after the surgical procedure is complete, disposable assembly(100) is immediately disposed of while reusable assembly (200) issterilized and otherwise processed for re-use. By way of example only,reusable assembly (200) may be sterilized in a conventional relativelylow temperature, relatively low pressure, hydrogen peroxidesterilization process. Alternatively, reusable assembly (200) may besterilized using any other suitable systems and techniques (e.g.,autoclave, etc.). In some versions, reusable assembly (200) may besterilized and reused approximately 100 times. Alternatively, reusableassembly (200) may be subject to any other suitable life cycle. Forinstance, reusable assembly (200) may be disposed of after a single use,if desired. While disposable assembly (100) is referred to herein asbeing “disposable,” it should be understood that, in some instances,disposable assembly (100) may also be sterilized and otherwise processedfor re-use. By way of example only, disposable assembly (100) may besterilized and reused approximately 2-30 times, using any suitablesystems and techniques. Alternatively, disposable assembly (100) may besubject to any other suitable life cycle.

In some versions, disposable assembly (100) and/or reusable assembly(200) includes one or more features that are operable to track usage ofthe corresponding assembly (100, 200), and selectively restrictoperability of the corresponding assembly (100, 200) based on use. Forinstance, disposable assembly (100) and/or reusable assembly (200) mayinclude one or more counting sensors and a control logic (e.g.,microprocessor, etc.) that is in communication with the countingsensor(s). The counting sensor(s) may be able to detect the number oftimes the ultrasonic transducer of instrument (10) is activated, thenumber of surgical procedures the corresponding assembly (100, 200) isused in, the number of trigger closures, and/or any other suitableconditions associated with use. The control logic may track data fromthe counting sensor(s) and compare the data to one or more thresholdvalues. When the control logic determines that one or more thresholdvalues have been exceeded, the control logic may execute a controlalgorithm to disable operability of one or more components in thecorresponding assembly (100, 200). In instances where the control logicstores two or more threshold values (e.g., a first threshold for numberof activations and a second threshold for number of surgical procedures,etc.), the control logic may disable operability of one or morecomponents in the corresponding assembly (100, 200) the first time oneof those thresholds is exceeded, or on some other basis.

In versions where a control logic is operable to disable instrument (10)based on the amount of use, the control logic may also determine whetherinstrument (10) is currently being used in a surgical procedure, andrefrain from disabling instrument (10) until that particular surgicalprocedure is complete. In other words, the control logic may allow theoperator to complete the current surgical procedure but preventinstrument (10) from being used in a subsequent surgical procedure.Various suitable forms that counters or other sensors may take will beapparent to those of ordinary skill in the art in view of the teachingsherein. Various suitable forms that a control logic may take will alsobe apparent to those of ordinary skill in the art in view of theteachings herein. Similarly, various suitable control algorithms thatmay be used to restrict usage of instrument (10) will be apparent tothose of ordinary skill in the art in view of the teachings herein. Ofcourse, some versions of instrument (10) may simply omit features thattrack and/or restrict the amount of usage of instrument (10).

Disposable assembly (100) of the present example comprises a bodyportion (110), a shaft assembly (150) extending distally from bodyportion (110), and an end effector (180) located at the distal end ofshaft assembly (150). As best seen in FIGS. 2-4, end effector (180) ofthis example comprises a clamp arm (182) and an ultrasonic blade (190).Clamp arm (182) includes a clamp pad (184), which faces blade (190). Asshown in FIGS. 3A-3B and as will be described in greater detail below,clamp arm (182) is pivotable toward and away from blade (190) toselectively compress tissue between clamp pad (184) and blade (190). Asseen in FIG. 4, blade (190) is an integral feature of the distal end ofan acoustic waveguide (192), which extends coaxially through tubes (152,170), and which is configured to communicate ultrasonic vibrations toblade (190) as will be described in greater detail below.

Shaft assembly (150) comprises an outer tube (152) and an inner tube(170) and a rotation knob (112). Rotation knob (112) is operable torotate the entire shaft assembly (150) and end effector (180) relativeto reusable assembly (200) about a longitudinal axis of shaft assembly(150). In some versions, rotation knob (112) is operable to selectivelylock the angular position of shaft assembly (150) and end effector (180)relative to reusable assembly (200) about the longitudinal axis of shaftassembly (150).

Outer tube (152) is operable to translate longitudinally relative toinner tube (170) to selectively pivot clamp arm (182) toward and awayfrom blade (190). To accomplish this, and as best seen in FIG. 4,integral pin features (186) of clamp arm (182) pivotally secure a firstportion of clamp arm (182) to a distally projecting tongue (154) ofouter tube (152); while an inserted pin (188) pivotally secures a secondportion of clamp arm (182) to a distally projecting tongue (172) ofinner tube (170). Thus, as can be seen in the transition from FIG. 3A toFIG. 3B, tubes (152, 170) cooperate to pivot clamp arm (182) towardblade (190) when outer tube (152) is retracted proximally relative toinner tube (170). It should be understood that clamp arm (182) may bepivoted back away from blade (190) (e.g., from the position shown inFIG. 3B to the position shown in FIG. 3A) by translating outer tube(152) distally relative to inner tube (170), in reverse of the operationshown in FIGS. 3A-3B. In an exemplary use, clamp arm (182) may bepivoted toward blade (190) to grasp, compress, seal, and sever tissuecaptured between clamp pad (184) and blade (190). Clamp arm (182) may bepivoted away from blade (190) to release tissue from between clamp pad(184) and blade (190); and/or to perform blunt dissection of tissueengaging opposing outer surfaces of clamp arm (182) and blade (190).

Shaft assembly (150) includes a distal seal (193), which is coaxiallyinterposed between the outer diameter of waveguide (192) and the innerdiameter of inner tube (170). In the present example, distal seal (193)comprises an elastomeric material (e.g., rubber, silicone, etc.). Distalseal (193) is located at a position corresponding to a node associatedwith ultrasonic vibrations that are communicated through waveguide(192).

As seen in FIG. 1, reusable assembly (200) comprises a handle housing(202). Housing (202) defines a pistol grip (204) while disposableassembly (100) includes a trigger (120) pivotally coupled to housingwhen assemblies (100, 200) are sufficiently coupled. Clamp arm (182) iscoupled with trigger (120) such that clamp arm (182) is pivotable towardultrasonic blade (190) in response to pivoting of trigger (120) towardpistol grip (204); and such that clamp arm (182) is pivotable away fromultrasonic blade (190) in response to pivoting of trigger (120) awayfrom pistol grip (204). While reusable assembly (200) includes a pistolgrip (204) in this example, it should be understood that any othersuitable kind of grip may be used. Reusable assembly (200) includes abattery (not shown), a generator (not shown), and an ultrasonictransducer assembly (not shown). Disposable assembly (100) also includesan activation button (126) electrically coupled to reusable assembly(200) when assemblies (100, 200) are sufficiently coupled. Battery (notshown) is operable to provide electrical power to generator (not shown);generator (not shown) is operable to provide electrical power toultrasonic transducer assembly (not shown); and ultrasonic transducerassembly is operable to convert electrical power into ultrasonicvibrations. Activation button (126) may activate ultrasonic transducerassembly to convert electrical power into ultrasonic vibrations.

When waveguide (192) is sufficiently coupled with transducer assembly(not shown), ultrasonic vibrations that are generated by transducerassembly (not shown) are communicated along waveguide (192) to reachblade (190). In the present example, the distal end of blade (190) islocated at a position corresponding to an anti-node associated withresonant ultrasonic vibrations communicated through waveguide (192), inorder to tune the acoustic assembly to a preferred resonant frequencyf_(o) when the acoustic assembly is not loaded by tissue. Whentransducer assembly (not shown) is energized, the distal end of blade(190) is configured to move longitudinally in the range of, for example,approximately 10 to 500 microns peak-to-peak, and in some instances inthe range of about 20 to about 200 microns at a predetermined vibratoryfrequency f_(o) of, for example, 55.5 kHz. When transducer assembly (notshown) of the present example is activated, these mechanicaloscillations are transmitted through waveguide (192) to reach blade(190), thereby providing oscillation of blade (190) at the resonantultrasonic frequency. Thus, when tissue is secured between blade (190)and clamp pad (184), the ultrasonic oscillation of blade (190) maysimultaneously sever the tissue and denature the proteins in adjacenttissue cells, thereby providing a coagulative effect with relativelylittle thermal spread. In some versions, an electrical current may alsobe provided through blade (190) and/or clamp pad (184) to also seal thetissue.

By way of example only, instrument (10) may be further constructed andoperable in accordance with at least some of the teachings of U.S.patent application Ser. No. 14/868,574, entitled “Ultrasonic SurgicalInstrument with Removable Handle Assembly,” filed Sep. 29, 2015,published as U.S. Pub. No. 2016/0015419 on Jan. 21, 2016, the disclosureof which is incorporated by reference herein; and/or U.S. patentapplication Ser. No. 14/623,812, entitled “Ultrasonic SurgicalInstrument with Removable Handle Assembly,” filed Feb. 17, 2015, issuedas U.S. Pat. No. 10,010,340 on Jul. 3, 2018, the disclosure of which isincorporated by reference herein. Further exemplary features andoperabilities for disposable assembly (100) and reusable assembly (200)will be described in greater detail below, while other variations willbe apparent to those of ordinary skill in the art in view of theteachings herein.

II. Exemplary Cleaning Devices

In some instances during a surgical procedure, tissue debris, coagulatedblood, and/or other substances may tend to collect on the outerdiameters of ultrasonic blade (190) and acoustic waveguide (192), theinner diameters of distally projecting tongues (154, 172) and inner tube(170), as well as the distal portion of seal (193) itself. Due to themechanical vibrations of acoustic waveguide (192) and ultrasonic blade(190), this collected debris, etc., may cake onto and stick to the abovemotioned areas excessively. If debris, etc. does collect onto the abovementioned areas excessively, performance of instrument (10) may benegatively affected. For instance, collected debris, etc. may interferewith mechanical oscillations transmitted through waveguide (192) andblade (190).

In view of the foregoing, it may be beneficial to have a cleaning devicethat is capable of easily removing such debris, etc. during a surgicalprocedure. Additionally or alternatively, it may be beneficial to have acleaning that is device capable of removing such debris, etc. in betweensurgical procedures. Several merely illustrative examples of suchcleaning devices are described in greater detail below. While thefollowing examples are provided in the context of cleaning instrument(10), it should be understood that the below described cleaning devicesmay also be used with various other kinds of instruments, including butnot limited to the various instruments described in the variousreferences that are cited herein.

A. Exemplary Detachable Cleaning Devices

In some instances, it may be desirable to provide an end effector and/orshaft assembly cleaning device that is separate from (or separable from)instrument (10). This may allow the cleaning device to be used withconventional instruments without requiring modification to theconventional instruments. This may also enable more than one cleaningdevice to be used on a single instrument (10), such as during a longsurgical procedure where a first cleaning device may become unusable dueto repeated cleaning. The following discussion provides several merelyillustrative examples of end effector and/or shaft assembly cleaningdevices that are separate from (or separable from) instrument (10).

1. Exemplary Cleaning Device with Helical Brush and Fluid Port

FIGS. 5-10B show an exemplary detachable cleaning device (300) that maybe used to clean portions of end effector (180) and shaft assembly (150)of instrument (10). As best seen in FIGS. 5-6, cleaning device (300)includes a handle assembly (310), a brush assembly (320), and aremovable cap (302).

Handle assembly (310) includes a luer fitting (315), a flexible handle(314), and a flexible shaft (312). Flexible handle (314) extends fromluer fitting (315) while flexible shaft (312) extends from flexiblehandle (314). Luer fitting (315), flexible handle (314), and flexibleshaft (312) may be unitarily connected. Alternatively, luer fitting(315), flexible handle (314), and flexible shaft (312) may be connectedby an interference fit or any suitable manner apparent to one havingordinary skill in the art in view of the teachings herein. Flexibleshaft (312) is dimensioned to receive the outer diameters of ultrasonicblade (190) and waveguide (192). However, flexible shaft (312) is alsodimensioned to fit within the inner diameters of distally projectingtongues (154, 172) and inner tube (170).

A plurality of protrusions (316) extend along the length of flexiblehandle (314) and terminate into a plurality of stops (318). Protrusions(316) may be grasped by an operator in order to manipulate handleassembly (310) in various ways, such as rotating handle assembly (310)about its own longitudinal axis. Stops (318) may contact brush assembly(320) to prevent brush assembly (320) from moving proximally along thelength of flexible handle (314).

Luer fitting (315), flexible handle (314) and flexible shaft (312)together define a lumen (311). Lumen (311) is dimensioned to receiveultrasonic blade (190). Flexible handle (314) and flexible shaft (312)have sufficient resilient flexibility in order to conform to thecontours of ultrasonic blade (190) in versions where blade (190) has acurved longitudinal profile. Lumen (311) may have a varying diameteralong the length of handle assembly (310). Alternatively, lumen (311)may have a uniform diameter along the length of handle assembly (310).As will be described in greater detail below, lumen (311) may providefluid communication from a fluid source to selected portions of endeffector (180) and shaft assembly (150). Luer fitting (315) is thusconfigured to attach a fluid source with lumen (311) of handle assembly(310).

Removable cap (302) includes a grip (304) and a plug (306). Plug (306)is dimensioned for an interference fit with the portion of lumen (311)defined by luer fitting (315). As best seen in FIGS. 7-8, removable cap(302) may be removed from the rest of handle assembly (310). Theinterference fit between cap (302) and flexible handle (314) enables anoperator to remove assembled cleaning device (300) from rotation knob(112) of instrument (10) by pulling grip (304) of cap (302), withoutremoving cap (302) from the rest of cleaning device (300), as shown inFIG. 10A-10B; but weak enough to allow an operator to later remove cap(302) from the rest of cleaning device (300) after cleaning device (300)has been pulled from rotation knob (112). Attentively, plug (306) maycomprise external threading while the portion of lumen (311) defined byluer fitting (315) may comprise complementary internal threading.Therefore, an operator may be able to remove assembled cleaning device(300) from rotation knob (112) by pulling cap (302); and then remove cap(302) form the rest of cleaning device (300) by rotating cap (302)relative to handle assembly (310). Removable cap (302) may beselectively connected to handle assembly (320) in any other suitablemanner as would be apparent to one having ordinary skill in the art inview of the teachings herein.

Brush assembly (320) includes a brush body (322) wrapped around a wire(324). Wire (324) and brush body (322) form a helical shape in order todefine a tunnel (326). As seen in FIGS. 7-9B, wire (324) is dimensionedto fit over the outer diameter of flexible shaft (312). A portion ofbrush assembly (320) is connected to handle assembly (310) via aninterference fit between wire (324) and flexible shaft (312). Therefore,a portion of brush body (322) is also connected to handle assembly(310). However, brush assembly (320) may be connected to handle assembly(310) by any other suitable manner that would be apparent to one havingordinary skill in the art.

As will be described in greater detail below, brush assembly (320) isdimensioned to receive blade (190) and portions of waveguide (192)within tunnel (326) while fitting within the inner diameter of innertube (170) and distally projecting tongues (154, 172). Wire (324) mayhave sufficient resilient flexibility in order to conform to thecontours of ultrasonic blade (190) in versions where blade (190) has acurved longitudinal profile. Brush body (322) is sufficiently resilientto compress within tight spaces and later return to its original shapewhen exiting tight spaces.

Brush body (322) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (322) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (322) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

As mentioned above, cap (302) may be selectively removed from luerfitting (315). Luer fitting (315) may also couple to a fluid source.FIG. 8 shows cap (302) removed from handle assembly (310) while luerfitting (315) is coupled to a fluid source (30) via a conduit (32) and aluer attachment (36). Fluid source (30) may be a fluid filled syringe, apump, or any other suitable fluid source as will be apparent to onehaving ordinary skill in the art in view of the teachings herein. Luerattachment (36) may provide a fluid tight seal with luer fitting (315).Fluid may thus travel from fluid source (30), through conduit (32) andlumen (311) to exit the end of lumen (311) defined by flexible shaft(312). As will be described in greater detail below, cleaning device(300) may be inserted within a distal portion of shaft assembly (150) inorder for brush body (322) to remove excess debris. If cleaning device(300) is inserted within shaft assembly (150), fluid may be deliveredwithin shaft assembly (150) to flush out excess debris removed from theouter diameters of blade (190) and waveguide (192), as well as excessdebris removed from the inner diameters of distally projecting tongues(152, 172) and inner tube (170).

FIGS. 9A-9B show cleaning device (300) being inserted over the outerdiameters of ultrasonic blade (190) and acoustic waveguide (192) andwithin the inner diameters of distally projecting tongues (154, 172) andinner tube (170). As mentioned above, brush assembly (320), flexiblehandle (314), and flexible shaft (312) all have sufficient flexibilityand rigidity in order to conform to the contours of ultrasonic blade(190) in versions where blade (190) has a curved longitudinal profile.Therefore, while blade (190) is shown as having a straight longitudinalprofile, cleaning device (300) is also capable of working with a curvedultrasonic blade (190).

With flexible shaft (312) and brush assembly (320) inserted within shaftassembly (150), as shown in FIG. 9B, an operator may twist cleaningdevice (300) about its longitudinal axis by gripping flexible handle(314) and protrusions (316). An operator may also actuate cleaningdevice (300) toward and away from proximal seal (193) in alongitudinally reciprocating motion to encourage contact between brushbody (322) and surrounding components. Due to brush body (322) beingsufficiently resilient to compress within tight spaces and later returnto its original shape out of tight spaces, brush body (322) may makecontact with the outer diameters of blade (190) and waveguide (192)while also making contact with the inner diameters of distallyprojecting tongues (152, 172) and inner tube (170). Additionally, due tobrush body (322) having abrasive qualities, contact made by brush body(322) may remove debris caked onto the outer diameters of blade (190)and waveguide (192); and remove debris caked onto the inner diameters ofdistally projecting tongues (152, 172) and inner tube (170). An operatormay then attach fluid source (30) to cleaning device (300) via luerattachment (36) and luer fitting (315), as shown in FIG. 8, to deliverfluid to wash out removed debris.

As best shown in FIGS. 10A-10B, rotation knob (112) includes a pluralityof recesses (114) designed to removably house multiple cleaning devices(300), providing a convenient location for the operator to accesscleaning devices (300). While the current example shows knob (112)housing cleaning devices (300), it is envisioned that knob (112) mayhave recesses (114) dimensioned to house any of the detachable cleaningdevices described below. While three cleaning devices (300) and threerecesses (114) are shown in the current example, any number of cleaningdevices (300) may be housed within rotation knob (112) with any numberof corresponding recesses (114) as would be apparent to one havingordinary skill in the art. While recesses (114) are located on rotationknob (112) in the present example, it should be understood that recesses(114) may be located at any other suitable location on instrument (10)that would be apparent to a person having ordinary skill in the art.

Because there are multiple cleaning devices (300) located on knob (112),an operator may be encouraged to discard a specific cleaning device(300) after one use. Additionally, cleaning device (300) may have afeature on flexible handle (310) to prevent or discourage reassembly ofa removed cleaning device (300) back into recess (114). As mentionedabove, cleaning devices (300) may be used during a surgical procedure orbetween surgical procedures. If cleaning devices (300) are primarily tobe used in between surgical procedures, the number of cleaning deviceson knob (112) may indicate the number of surgical procedures thatdisposable assembly (100) may be used.

2. Exemplary Cleaning Device with Brush Woven into Shaft

FIG. 11 shows an alternative brush assembly (400) that may beincorporated at the end of flexible shaft (312). Brush assembly (400) ofthis example includes a hollow shaft (421) having flexible ribs (428).Flexible ribs (428) allow hollow shaft (421) to have sufficientresilient flexibility such that hollow shaft (421) may conform to thecontours of ultrasonic blade (190) in versions where blade (190) has acurved longitudinal profile. Hollow shaft (421) may extend from flexibleshaft (312) in such a way as to continue to define lumen (311). Hollowshaft (421) is thus dimensioned to receive ultrasonic blade (190) andwaveguide (192). Additionally, and similar to flexible shaft (312),hollow shaft (421) is dimensioned to fit within distally projectingtongues (154, 172) and inner tube (170). Hollow shaft (421) may alsopartially define lumen (311) for providing fluid communication from afluid source to selected portions of end effector (180) and shaftassembly (150) as described above.

Hollow shaft (421) also defines a plurality of apertures (425).Apertures (425) house a wire (424) weaving in and out of apertures(425). Wire (424) has a plurality of bristles (422) extending radiallyoutwardly from wire (424). Bristles (422) are exposed within the innerdiameter and outer diameter of hollow shaft (421). Bristles (422) aresufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Additionally, bristles(422) may have sufficient abrasive qualities to remove surgical debriscaked onto the outer diameters of blade (190) and waveguide (192), aswell as surgical debris caked onto the inner diameters of distallyprojecting tongues (152, 172) and inner tube (170). Bristles (422) maybe made of any suitable material known to one having ordinary skill inthe art in view of the teachings herein.

As mentioned above, bristles (422) are exposed to the inner diameter andthe outer diameter of hollow shaft (421). Additionally, hollow shaft(421) is dimensioned to fit around the outer diameters of blade (190)and waveguide (192); and to fit within the inner diameters of distallyprojecting tongues (154, 172) and inner tube (170). Therefore, anoperator may insert hollow shaft (421) over blade (190) and waveguide(192), and within distally projecting tongues (154, 172) and inner tube(170), while the abrasive qualities of bristles (422) may help removesurgical debris caked onto blade (190), waveguide (192), distallyprojecting tongues (152, 172), and inner tube (170).

Hollow shaft (421) may be unitarily fixed to flexible shaft (312).Alternatively, hollow shaft (421) may be dimensioned for an interferencefit with flexible shaft (312). Hollow shaft (421) may be fixed relativeto flexible shaft (312) in any suitable manner apparent to one havingordinary skill in the art in view of the teachings herein.

3. Exemplary Cleaning Device with Brush Wrapping Around and into Shaft

FIGS. 12-18 show another exemplary cleaning device that may be used andstored within instrument (10). As best seen in FIGS. 12 and 14, cleaningdevice (500) includes a handle assembly (510), a brush assembly (520),and a removable cap (502). Handle assembly (510) is substantiallysimilar to handle assembly (310) mentioned above. Handle assembly (510)thus includes a flexible shaft (512), flexible handle (514), a pluralityof projections (516), a plurality of stops (518), and a luer fitting(515). These components are all substantially similar to flexible shaft(312), flexible handle (314), plurality of projections (316), pluralityof stops (318), and luer fitting (315) described above, respectively.Handle assembly (510) defines a lumen (511) that may provide fluidcommunication from a fluid source to selected portions of end effector(180) and shaft assembly (150) as described above.

Flexible shaft (512) is dimensioned to receive the outer diameters ofultrasonic blade (190) and waveguide (192). However, flexible shaft(512) is also dimensioned to fit within the inner diameters of distallyprojecting tongues (154, 172) and inner tube (170).

Removable cap (502) is substantially similar to removable cap (302)described above. Therefore, removable cap (502) includes grips (504) andplug (506), which are substantially similar to grips (304) and plug(306) described above, respectively.

Brush assembly (520) includes a brush body (522) wrapped around a wire(524) and a hollow shaft (521). As best seen in FIG. 15, hollow shaft(521) defines a plurality of recesses (526), a plurality of axial slots(528), and a plurality of diagonal slots (529). Recesses (526), axialslots (528) and diagonal slots (529) may help hollow shaft (521) providesufficient resilient flexibility such that hollow shaft (521) mayconform to the contours of ultrasonic blade (190) in versions whereblade (190) has a curved longitudinal profile.

Hollow shaft (521) extends from flexible shaft (512) in such a way as tocontinue to define lumen (511). Hollow shaft (521) is thus dimensionedto receive ultrasonic blade (190) and waveguide (192). Additionally, andsimilar to flexible shaft (512), hollow shaft (521) is dimensioned tofit within distally projecting tongues (154, 172) and inner tube (170).Hollow shaft (521) also partially defines lumen (511) for providingfluid communication from a fluid source to selected portions of endeffector (180) and shaft assembly (150) as described above. Hollow shaft(521) may be unitarily fixed to flexible shaft (512). Alternatively,hollow shaft (521) may be dimensioned for an interference fit withflexible shaft (512). Hollow shaft (521) may be fixed relative toflexible shaft (512) in any suitable manner apparent to one havingordinary skill in the art in view of the teachings herein.

Brush body (522) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (522) issufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Brush body (522) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (522) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

As best seen in FIGS. 17-18, brush body (522) and wire (524) wrap aroundthe outer diameter of hollow shaft (521) in such a way that brush body(522) and wire (524) partially rest within both apertures (526) anddiagonal slots (529). Brush body (522) is wrapped around aperture (526)and diagonal slots (529) with sufficient force to compress portions ofbrush body (522) within aperture (526) and diagonal slots (529). Thus,as best seen in FIGS. 13 and 18, a portion of brush body (522) isexposed adjacent to the inner diameter of hollow shaft (521) as well asthe outer diameter of hollow shaft (521). As mentioned above, hollowshaft (521) is dimensioned to fit around the outer diameters of blade(190) and waveguide (192); and to fit within the inner diameters ofdistally projecting tongues (154, 172) and inner tube (170). An operatormay thus insert hollow shaft (421) over blade (190) and waveguide (192)and within distally projecting tongues (153, 172) and inner tube (170),and the abrasive qualities of brush body (522) may help remove surgicaldebris caked onto blade (190), waveguide (192), distally projectingtongues (152, 172) and inner tube (170).

FIG. 19 shows another exemplary cleaning device (600) that may be usedand stored within instrument (10). Cleaning device (600) includes ahandle assembly (610) and a brush assembly (620). Cleaning device (600)may also include a cap (not shown) that is substantially similar to cap(302, 502) described above. Handle assembly (610) includes a flexibleshaft (612), flexible handle (614), a plurality of protrusions (616), aplurality of stops (618) and a luer fitting (not shown) substantiallysimilar to flexible shaft (512), flexible handle (514), plurality ofprotrusions (516), plurality of stops (518) and luer fitting (515)described above. Handle assembly (610) defines a lumen (611) that issubstantially similar to lumen (511) described above.

Flexible shaft (612) is dimensioned to receive the outer diameters ofultrasonic blade (190) and waveguide (192). Flexible shaft (612) is alsodimensioned to fit within the inner diameters of distally projectingtongues (154, 172) and inner tube (170).

Brush assembly (620) includes a brush body (622), a wire (624), aplurality of recesses (626) and a plurality of diagonal slots (629), allsubstantially similar to brush body (522), wire (524), plurality ofrecesses (526) and plurality of diagonal slots (529) mentioned above.However, the only difference between brush assembly (620) and brushassembly (520) described above is that brush assembly (620) does nothave a plurality of axial slots (528).

4. Exemplary Cleaning Device with Axially Extending Brushes

FIGS. 20-22 show another exemplary cleaning device (700) that may beused and stored within instrument (10). As best seen in FIGS. 21-22,cleaning device (700) includes a handle assembly (710), a brush assembly(720), and a removable cap (not shown). Handle assembly (710) issubstantially similar to handle assembly (310, 510) mentioned above.Handle assembly (710) thus includes a flexible shaft (712), flexiblehandle (714), a plurality of projections (716), a plurality of stops(718), and a luer fitting (not shown). These components are allsubstantially similar to flexible shaft (312, 512), flexible handle(314, 514), plurality of projections (316, 516), plurality of stops(318, 518), and luer fitting (315, 515) described above, respectively.Handle assembly (710) defines a lumen (711) that may provide fluidcommunication from a fluid source to selected portions of end effector(180) and shaft assembly (150) as described above.

Flexible shaft (712) is dimensioned to receive the outer diameters ofultrasonic blade (190) and waveguide (192). However, flexible shaft(712) is also dimensioned to fit within the inner diameters of distallyprojecting tongues (154, 172) and inner tube (170).

Brush assembly (720) includes four brush bodies (722) wrapped aroundfour respective wires (724) and a hollow shaft (721). Each wire (724)extends longitudinally adjacent to the inner diameter and the outerdiameter of hollow shaft (721) and wraps around the distal end of hollowshaft (721). Thus, a first portion of each brush body (722) is locatedwithin the inner diameter of hollow shaft (721) and a second portion ofeach brush body (722) is located adjacent to the outer diameter ofhollow shaft (721). Brush bodies (722) and wires (724) may be fixed tothe inner diameter of hollow shaft (721) or any other suitable locationapparent to one having ordinary skill in the art. Hollow shaft (721)defines a plurality of recesses (726). Recesses (726) may help hollowshaft (721) provide sufficient resilient flexibility such that hollowshaft (721) may conform to the contours of ultrasonic blade (190) inversions where blade (190) has a curved longitudinal profile.

Hollow shaft (721) extends from flexible shaft (712) in such a way as tocontinue to define lumen (711). Hollow shaft (721) is thus dimensionedto receive ultrasonic blade (190) and waveguide (192). Additionally, andsimilar to flexible shaft (312, 512, 712), hollow shaft (721) isdimensioned to fit within distally projecting tongues (154, 172) andinner tube (170). Hollow shaft (721) also partially defines lumen (711)for providing fluid communication from a fluid source to selectedportions of end effector (180) and shaft assembly (150) as describedabove. Hollow shaft (721) may be unitarily fixed to flexible shaft(712). Alternatively, hollow shaft (721) may be dimensioned for aninterference fit with flexible shaft (712). Hollow shaft (721) may befixed relative to flexible shaft (712) in any suitable manner apparentto one having ordinary skill in the art in view of the teachings herein.

Brush body (722) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (722) issufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Brush body (722) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (722) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

As mentioned above, brush bodies (722) and wires (724) are exposed bothwithin the inner diameter of hollow shaft (721) and adjacent to theouter diameter of hollow shaft (721). As mentioned above, hollow shaft(721) is dimensioned to fit around the outer diameters of blade (190)and waveguide (192); and to fit within the inner diameters of distallyprojecting tongues (154, 172) and inner tube (170). Therefore, anoperator may insert hollow shaft (721) over blade (190) and waveguide(192) and within distally projecting tongues (153, 172) and inner tube(170), and the abrasive qualities of brush body (722) may help removesurgical debris caked onto blade (190), waveguide (192), distallyprojecting tongues (152, 172) and inner tube (170).

5. Exemplary Cleaning Device with Double Helix Brush and Slidable BrushRetention Sheath

FIGS. 23-25C show another exemplary cleaning device (800) that may beused and stored within instrument (10). As best seen in FIGS. 23 and25C, cleaning device (800) includes a handle assembly (810), a brushassembly (820), and a removable cap (802). Removable cap (802) issubstantially similar to removable cap (302) described above.

As best seen in FIG. 25A, handle assembly (810) includes a flexiblehandle (814) defining pair of anchor holes (812) and axial grooves(819). It should be understood that one anchor hole (812) and one axialgroove (819) are obscured in FIG. 25A, as they are positioneddiametrically opposite to the shown anchor hole (812) and axial groove(819). Anchor holes (812) are spaced 180 degrees apart on flexiblehandle (814). Similarly, axial grooves (819) are spaced 180 degreesapart on flexible handle (814). While anchor holes (812) and axialgrooves (819) are spaced 180 degrees apart, this is not necessary. Anyother suitable spacing may be used as would be apparent to one havingordinary skill in the art.

Flexible handle (814) further includes a plurality of protrusions (816),a retention sleeve (818) slidably disposed around flexible handle (814),and a luer fitting (815). Luer fitting (815) is substantially similar toLuer fitting (315) mentioned above. Protrusions (816) are substantiallysimilar to protrusions (316) mentioned above. Flexible handle (814) issubstantially similar to flexible handle (314) mentioned above with thedifferences noted herein.

Brush assembly (820) includes a hollow shaft (821) and a wire (824)surrounded by a brush body (822). Hollow shaft (821) defines a pluralityof recesses (826), a helical groove (828), and a return hole (829).Hollow shaft (821) may possess sufficient resilient flexibility suchthat hollow shaft (821) may conform to the contours of ultrasonic blade(190) in versions where blade (190) has a curved longitudinal profile.Handle assembly (810) and brush assembly (820) define lumen (811). Lumen(811) may provide fluid communication from a fluid source to selectedportions of end effector (180) and shaft assembly (150) as describedabove. Hollow shaft (821) is dimensioned to receive ultrasonic blade(190) and waveguide (192). Additionally, and similar to flexible shaft(312, 512, 712), hollow shaft (821) is dimensioned to fit withindistally projecting tongues (154, 172) and inner tube (170).

Brush body (822) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (822) issufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Brush body (822) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (822) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

As best seen in FIG. 25B, brush body (822) and wire (824) extend insideanchor hole (812) and along axial groove (819) of flexible handle (814).Brush body (822) and wire (824) then wrap around every other helicalgroove (828) of hollow shaft (821) until brush body (822) and wire (824)extend through return holes (829). Brush body (822) and wire (824) thenwrap around every other helical groove (828) back toward handle assembly(810), extend along the opposite axial groove (819), and then extendinside the opposite anchor hole (812). Brush body (822) and wire (824)thus form a dual helix configuration.

And shown in FIG. 25C, retention sleeve (818) is the moved into aretaining position to cover the portion of brush body (822) and wire(824) extending inside anchor hole (812). Retention sleeve (818) thusretains brush body (822) and wire (824) in place when retention sleeveis in the distal position shown in FIG. 25C. Other suitable ways inwhich brush body (822) and wire (824) may be selectively retainedrelative to shaft (821) will be apparent to those of ordinary skill inthe art in view of the teachings herein.

Brush body (822) and wire (824) wrap around the outer diameter of hollowshaft (821) in such a way that brush body (822) and wire (824) partiallyrest within recesses (826). Brush body (822) is wrapped around recesses(826) with sufficient force to compress portions of brush body (822)within recesses (826). Thus, as best seen in FIG. 24, a portion of brushbody (822) is exposed to the inner diameter of hollow shaft (821) aswell as the outer diameter of hollow shaft (821). As mentioned above,hollow shaft (821) is dimensioned to fit around the outer diameters ofblade (190) and waveguide (192); and to fit within the inner diametersof distally projecting tongues (154, 172) and inner tube (170). Anoperator may thus insert hollow shaft (821) over blade (190) andwaveguide (192) and within distally projecting tongues (153, 172) andinner tube (170), and the abrasive qualities of brush body (822) mayhelp remove surgical debris caked onto blade (190), waveguide (192),distally projecting tongues (152, 172) and inner tube (170).

6. Exemplary Cleaning Device with Single Helix Brush

FIGS. 26-28 show another exemplary cleaning device (900) that may beused and stored within instrument (10). As best seen in FIGS. 26-27,cleaning device (900) includes a luer fitting (915), a flexible handle(914), a hollow shaft (921), and a brush body (922). Luer fitting (915)may be substantially similar to luer fitting (315) described above.Cleaning device (900) defines a lumen (911). Therefore, lumen (911) mayprovide fluid communication from a fluid source to selected portions ofend effector (180) and shaft assembly (150) as described above.

Hollow shaft (921) defines a helical groove (928) and a plurality ofrecesses (926). Hollow shaft (921) and flexible handle (914) may possesssufficient resilient flexibility such that hollow shaft (921) mayconform to the contours of ultrasonic blade (190) in versions whereblade (190) has a curved longitudinal profile. Hollow shaft (921) isdimensioned to receive ultrasonic blade (190) and waveguide (192).Additionally, and similar to flexible shaft (312, 512, 712), hollowshaft (921) is dimensioned to fit within distally projecting tongues(154, 172) and inner tube (170).

Brush body (922) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (922) issufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Brush body (922) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (922) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

Brush body (922) may be wrapped around a wire (not shown), similar tobrush body (322, 522, 622, 722, 822). Similar to cleaning device (800),brush body (922) wraps around helical groove (928). While cleaningdevice (800) had a double helix configuration, helical groove (928) hasa single helix configuration in this example, such that brush body (922)does not wrap back around hollow shaft (921). It should be understoodthat cleaning device (900) may include a retention sleeve similar toretention sleeve (818); or some other component that is configured toremovably retain brush body (922) relative to shaft (921).

Brush body (922) wraps around the outer diameter of hollow shaft (921)in such a way that brush body (922) partially rests within recesses(926). Brush body (922) is wrapped around recesses (926) with sufficientforce to compress portions of brush body (922) within recesses (926).Thus, as best seen in FIG. 28, a portion of brush body (922) is exposedto the inner diameter of hollow shaft (921) as well as the outerdiameter of hollow shaft (921). As mentioned above, hollow shaft (921)is dimensioned to fit around the outer diameters of blade (190) andwaveguide (192); and to fit within the inner diameters of distallyprojecting tongues (154, 172) and inner tube (170). An operator may thusinsert hollow shaft (921) over blade (190) and waveguide (192) andwithin distally projecting tongues (153, 172) and inner tube (170), andthe abrasive qualities of brush body (922) may help remove surgicaldebris caked onto blade (190), waveguide (192), distally projectingtongues (152, 172) and inner tube (170).

7. Exemplary Cleaning Device with Multi-Helical Brushes

FIG. 29 shows another exemplary cleaning device (1000) that may be usedand stored within instrument (10). Cleaning device (1000) includes ahandle assembly (1010) and a brush assembly (1020). Handle assembly(1010) is removable from brush assembly (1020). However, handle assembly(1010) may have an interference fit with brush assembly (1020) such thatwhen handle assembly (1010) slides onto brush assembly (1010), asufficient frictional force is provided to prevent handle assembly(1010) from sliding off of brush assembly (1020).

Handle assembly (1010) includes a luer fitting (1015) and a flexiblehandle (1014). Luer fitting (1015) and flexible handle (1014) may besubstantially similar to luer fitting (315) and flexible handle (314)described above.

Brush assembly (1020) includes a plurality of brush bodies (1022) and ahollow shaft (1021) with a plurality of apertures (1026) on one end anda plurality of protrusions (1024) on the other end. Hollow shaft (1021)may possess sufficient resilient flexibility such that hollow shaft(1021) may conform to the contours of ultrasonic blade (190) in versionswhere blade (190) has a curved longitudinal profile. Handle assembly(1010) and brush assembly (1020) define lumen (1011). Lumen (1011) mayprovide fluid communication from a fluid source to selected portions ofend effector (180) and shaft assembly (150) as described above. Hollowshaft (1021) is dimensioned to receive ultrasonic blade (190) andwaveguide (192). Additionally, and similar to flexible shaft (312, 512,712), hollow shaft (1021) is dimensioned to fit within distallyprojecting tongues (154, 172) and inner tube (170).

Brush body (1022) includes a plurality of bristles (not shown). Suchbristles may have any suitable degree of stiffness. Brush body (1022) issufficiently resilient to compress within tight spaces and later returnto its original shape when exiting tight spaces. Brush body (822) mayhave sufficient abrasive qualities to remove surgical debris caked ontothe outer diameters of blade (190) and waveguide (192), as well assurgical debris caked onto the inner diameters of distally projectingtongues (152, 172) and inner tube (170). Brush body (822) may be made ofany suitable material known to one having ordinary skill in the art inview of the teachings herein.

Each brush body (1022) extends through one aperture (1026), along hollowshaft (1021) along a respective helical path, and wraps around aprotrusion (1024) in order to travel back along hollow shaft (1021).Thus, the portion of brush body (1022) wrapped around protrusion (1024)is located adjacent to the inner diameter of hollow shaft (1021); whilethe portion of brush body (1022) extending helically along hollow shaft(1021) is located adjacent to the outer diameter of hollow shaft (1021).An operator may therefore insert hollow shaft (1021) over blade (190)and waveguide (192) and within distally projecting tongues (153, 172)and inner tube (170). The abrasive qualities of brush body (1022) mayhelp remove surgical debris caked onto blade (190), waveguide (192),distally projecting tongues (152, 172) and inner tube (170).

8. Exemplary Cleaning Device with Abrasive Material and Circular Shaft

FIG. 30 shows another exemplary cleaning device (1100) that may be usedand stored within instrument (10). Cleaning device (1100) includes ahandle assembly (1110) and a brush assembly (1120). Handle assemblyincludes a luer fitting (1115), a flexible handle (1114), and aplurality of protrusions (1116); which may be substantially similar toluer fitting (315), flexible handle (314), and plurality of protrusions(316) mentioned above.

Brush assembly (1120) includes a hollow shaft (1121) covered withabrasive material (1122) on the inner diameter and the outer diameter ofhollow shaft (1121). Handle assembly (1110) and brush assembly (1120)define lumen (1111). Lumen (1111) may provide fluid communication from afluid source to selected portions of end effector (180) and shaftassembly (150) as described above. Hollow shaft (1121) is dimensioned toreceive ultrasonic blade (190) and waveguide (192). Additionally, andsimilar to flexible shaft (312, 512, 712), hollow shaft (1121) isdimensioned to fit within distally projecting tongues (154, 172) andinner tube (170).

By way of example only, abrasive material (1122) may comprise grit,knurling, ridges, and/or any other suitable kinds of abrasive surfacefeatures. Abrasive material (1122) may have sufficient abrasivequalities to remove surgical debris caked onto the outer diameters ofblade (190) and waveguide (192), as well as surgical debris caked ontothe inner diameters of distally projecting tongues (152, 172) and innertube (170). Abrasive material (1122) may be made of any suitablematerial known to one having ordinary skill in the art in view of theteachings herein.

It should be understood that an operator may insert hollow shaft (1121)over blade (190) and waveguide (192) and within distally projectingtongues (153, 172) and inner tube (170), and the abrasive qualities ofabrasive material (1122) may help remove surgical debris caked ontoblade (190), waveguide (192), distally projecting tongues (152, 172) andinner tube (170).

9. Exemplary Cleaning Device with Abrasive Material and Semi-CircularShaft

FIG. 31 shows another exemplary cleaning device (1200) that may be usedand stored within instrument (10). Cleaning device (1200) includes ahandle assembly (1210) and a brush assembly (1220). Handle assemblyincludes a luer fitting (1215), and a flexible handle (1214), which maybe substantially similar to luer fitting (315), and flexible handle(314), mentioned above.

Brush assembly (1220) includes a semicircular hollow shaft (1221)covered with abrasive material (1222) on the inner diameter and theouter diameter of semicircular hollow shaft (1221). Handle assembly(1210) and brush assembly (1220) define a partial lumen (1211). Partiallumen (1211) may provide fluid communication from a fluid source toselected portions of end effector (180) and shaft assembly (150) asdescribed above. Semicircular hollow shaft (1121) is dimensioned toreceive ultrasonic blade (190) and waveguide (192). Additionally, andsimilar to flexible shaft (312, 512, 712), semicircular hollow shaft(1221) is dimensioned to fit within distally projecting tongues (154,172) and inner tube (170).

By way of example only, abrasive material (1222) may comprise grit,knurling, ridges, and/or any other suitable kinds of abrasive surfacefeatures. Abrasive material (1222) may have sufficient abrasivequalities to remove surgical debris caked onto the outer diameters ofblade (190) and waveguide (192), as well as surgical debris caked ontothe inner diameters of distally projecting tongues (152, 172) and innertube (170). Abrasive material (1222) may be made of any suitablematerial known to one having ordinary skill in the art in view of theteachings herein.

It should be understood that an operator may insert hollow shaft (1221)over blade (190) and waveguide (192) and within distally projectingtongues (153, 172) and inner tube (170), and the abrasive qualities ofabrasive material (1122) may help remove surgical debris caked ontoblade (190), waveguide (192), distally projecting tongues (152, 172) andinner tube (170).

10. Exemplary Cleaning Device with Flexible Scraping Edge

FIGS. 32-34 show another exemplary cleaning device (1300) that may beused and stored within instrument (10). As best seen in FIG. 32,cleaning device (1300) includes a flexible shaft (1312), a flexiblehandle (1314), a plurality of projections (1316), a plurality of stops(1318), and a luer fitting (1315); all substantially similar to flexibleshaft (312), flexible handle (314), plurality of projections (316),plurality of stops (318), and luer fitting (315) described aboverespectively, with differences described below. Handle assembly (510)thus defines a lumen (1311) that may provide fluid communication from afluid source to selected portions of end effector (180) and shaftassembly (150) as described above.

Flexible shaft (1312) is dimensioned to receive ultrasonic blade (190)and waveguide (192). Additionally, flexible shaft (1312) is dimensionedto fit within distally projecting tongues (152, 172) and inner tube(170). An operator may thus insert flexible shaft (1312) within distallyprojecting tongues (152, 172) and inner tube (171) up to distal seal(193). Flexible shaft (1312) also includes a tapered edge (1320)terminating into an edge (1322). Edge (1322) is dimensioned to hug theouter diameter of ultrasonic blade (190) and waveguide (192) as flexibleshaft (1312) is inserted up to distal seal (193). Tapered edge (1320)may expand around blade (190) or waveguide (192) to accommodate thechange in diameter along the longitudinal profile of blade (190) orwaveguide (192). Edge (1322) may thus scrape off excess debris cakedonto blade (190) and waveguide (192) as flexible shaft (1312) isinserted toward distal seal (193).

B. Exemplary Integral Cleaning Devices

In some instances, it may be desirable to provide an end effector and/orshaft assembly cleaning device that is fully integrated into instrument(10). This may reduce the number of components that an operator mustmanipulate and track. Several merely illustrative examples of endeffector and/or shaft assembly cleaning devices that are fullyintegrated into instrument (10) are described in greater detail below.

1. Exemplary Shaft Assembly with Integral Translating Scraper

FIGS. 35A-36 show an alternative shaft assembly (1150) and end effector(1180) that may be incorporated into instrument (10) in place of shaftassembly (150) and end effector (180). Shaft assembly (1150) and endeffector (1180) may be configured and operable just like shaft assembly(150) and end effector (180) except for the differences described below.End effector (1180) includes a clamp arm (1182), clamp pad (1184), andblade (1190), that are substantially similar to clamp arm (182), clamppad (184) and blade (190) mentioned above. Shaft assembly (1150)includes a distal seal (1193), an acoustic waveguide (1192), an outertube (1152), and an inner tube (1170) that are substantially similar todistal seal (193), acoustic waveguide (192), outer tube (152) and innertube (170) mentioned above, with differences described below. Inner tube(1170) includes a distally projecting tongue (1172) that issubstantially similar to distally projecting tongue (172) mentionedabove. Outer tube (1152) includes a distally projecting tongue (1154)that is substantially similar to distally projecting tongue (154)mentioned above. Clamp arm (1182) is pivotally connected to pin (1188)and integral pin feature (1186) such that translation of outer tube(1152) pivots clamp arm (1182) toward and away from ultrasonic blade(1190).

Outer tube (1152) and inner tube (1170) together define a pair of slots(1156) in which a cleaning feature (1160) is housed. Slots (1156) aresized and arranged to accommodate relative movement between tubes (1152,1170) during actuation of clamp arm (1182), without interference fromcleaning feature (1160). Cleaning feature (1160) includes a pair ofgrips (1162) housed adjacent to outer tube (1152). Cleaning feature(1160) further includes a scraper (1164) extending from grips (1162)toward acoustic waveguide (1192). Scraper (1164) may be configured toencompass acoustic waveguide (1192).

As best seen in FIGS. 35A-35B, cleaning feature (1162) is capable oftraveling longitudinally from a first position to a second position.While cleaning feature (1160) is in the first position, as shown in FIG.35A, scraper (1164) is adjacent to distal seal (1193). An operator maythen actuate cleaning feature (1160) in the distal direction to thesecond position, as shown in FIG. 35B, by sliding grips (1162) in thedistal direction. Because scraper (1164) encompasses acoustic waveguide(1192), scraper (1164) may dislodge any excess surgical debris thatcaked onto the portion of acoustic waveguide (1192) in contact withscraper (1164).

2. Exemplary Shaft Assembly with Integral Translating and RotatingScraper

FIGS. 37-38 show another alternative shaft assembly (2150) and endeffector (2180) that may be incorporated into instrument (10) in placeof shaft assembly (150) and end effector (180). Shaft assembly (2150)and end effector (2180) may be configured and operable just like shaftassembly (150) and end effector (180) except for the differencesdescribed below. End effector (2180) includes a clamp arm (2182), clamppad (2184) and blade (2190) that are substantially similar to clamp arm(182), clamp pad (184) and blade (190) mentioned above. Shaft assembly(2150) includes a distal seal (2193), an acoustic waveguide (2192), anouter tube (2152), and an inner tube (2170) that are substantiallysimilar to distal seal (193), acoustic waveguide (192), outer tube (152)and inner tube (170) mentioned above, with differences described below.Inner tube (2170) includes a distally projecting tongue (2172) that issubstantially similar to distally projecting tongue (172) mentionedabove. Outer tube (2152) includes a distally projecting tongue (2154)that is substantially similar to distally projecting tongue (154)mentioned above. Clamp arm (2182) is pivotally connected to pin (2188)and integral pin feature (2186) such that translation of outer tube(2152) pivots clamp arm (2182) toward and away from ultrasonic blade(2190).

Outer tube (1152) and inner tube (1170) together define a plurality ofarched slots (2156) in which a cleaning feature (2160) is housed.Cleaning feature (2160) includes an annular grip (2162) located outsideouter tube (2152) and a plurality of scrapers (2164) extending withinarched slots (2156) towards acoustic waveguide (2192). Scrapers (2164)are dimensioned to make contact with acoustic waveguide (2192). As bestseen in FIG. 38, cleaning feature (2160) may travel along the pathprovided by arched slots (2156) if an operator rotates annular grip(2162). In particular, cleaning feature (2160) will travel angularlyabout the longitudinal axis while simultaneously translating along thelongitudinal axis while the operator rotates annular grip (2162). Whilecleaning feature (2160) travels along the path defined by arched slots(2156), scrapers (2164) travel helically along waveguide (2192) anddislodge any excess surgical debris that caked onto the portion ofacoustic waveguide (2192) in contact with scraper (2164).

3. Exemplary Scraping Ring

FIGS. 39-42B show a cleaning device (160) that may be readilyincorporated into shaft assembly (150) and end effector (180) describedabove. Cleaning feature (160) includes a body (162) fixed to a pair oflegs (168). Body (162) defines a channel (166) that is dimensioned tohouse a portion of acoustic waveguide (192). Body (162) also includes anangular array of scrapers (164) pointing toward acoustic waveguide(192). The points of scrapers (164) are intended to make contact withthe outer diameter of acoustic waveguide (192). As will be described ingreater detail below, cleaning device (160) is configured to translatealong a portion of acoustic waveguide (192) in response to translationof outer tube (2152), where scrapers (164) may dislodge surgical debriscaked onto acoustic waveguide (192).

Each leg (168) includes a kidney slot (169). As can be seen in FIGS.42A-42B, each kidney slot (169) is dimensioned to house integral pinfeature (186). Kidney slot (169) is dimensioned to make contact withintegral pin feature (186) as distally projecting tongue (154)translates. In other words, cleaning device (160) will translatelongitudinally along waveguide (192) in response to the action ofpivoting clamp arm (182) toward and away from blade (190). Integral pinfeature (186) cams against kidney slot (169) to translate cleaningdevice (160) in the proximal or distal direction relative to acousticwaveguide (192). However, the shape of kidney slot (169) is dimensionedsuch that legs (168) do not make contact with integral pin feature (186)as integral pin feature (186) travels in the vertical direction relativeto distally projecting tongue (154). Therefore, movement of cleaningdevice (160) is limited in the proximal and distal directions.

When cleaning device (160) translates relative to waveguide (192),scrapers (164) make contact with the outer diameter of acousticwaveguide (192), thereby dislodging surgical debris caked onto waveguide(192). In some versions, scrapers (164) are rigid. In some otherexamples, scrapers are flexible (e.g., elastomeric). Various suitablematerials that may be used to form scrapers (164) will be apparent tothose of ordinary skill in the art in view of the teachings herein.Similarly, various suitable properties that scrapers (164) may have willbe apparent to those of ordinary skill in the art in view of theteachings herein.

4. Exemplary Scrapers on Outer Tube

FIGS. 43-44 show a pair of alternative cleaning devices (260, 264) thatmay also be readily incorporated into shaft assembly (150) and endeffector (180) described above. As best shown in FIG. 43, top cleaningdevice (260) and bottom cleaning device (264) may be fixed to distallyprojecting tongue (154). Top cleaning device (260) and bottom cleaningdevice (264) each include a plurality of scrapers (262, 266)respectively. As can be seen in FIG. 44, scrapers (262, 266) arepositioned to make contact with acoustic waveguide (192) or blade (190).Therefore, as outer tube (152) translates in order to pivot clamp arm(182) relative to blade (190), scrapers (262, 264) also translaterelative to waveguide (192) and blade (190) to dislodge surgical debriscaked onto waveguide (192) and/or blade (190).

In some versions, scrapers (262, 266) are rigid. In some other examples,scrapers are flexible (e.g., elastomeric). Various suitable materialsthat may be used to form scrapers (262, 266) will be apparent to thoseof ordinary skill in the art in view of the teachings herein. Similarly,various suitable properties that scrapers (262, 266) may have will beapparent to those of ordinary skill in the art in view of the teachingsherein.

5. Exemplary Shaft Assembly with Flush Port

FIGS. 45A-47 show an alternative shaft assembly (3150) and end effector(3180) that may be incorporated into instrument (10) in place of shaftassembly (150) and end effector (180). Shaft assembly (3150) and endeffector (3180) may be configured and operable just like shaft assembly(150) and end effector (180) except for the differences described below.End effector (3180) includes a clamp arm (3182), clamp pad (3184) andblade (3190) that are substantially similar to clamp arm (182), clamppad (184) and blade (190) mentioned above, with the differencesdescribed below. Shaft assembly (3150) includes a distal seal (3193), anacoustic waveguide (3192), an outer tube (3152), and an inner tube(3170) that are substantially similar to distal seal (193), acousticwaveguide (192), outer tube (152) and inner tube (170) mentioned above,with differences described below. Inner tube (3170) includes a distallyprojecting tongue (3172) that is substantially similar to distallyprojecting tongue (172) mentioned above. Outer tube (3152) includes adistally projecting tongue (3154) that is substantially similar todistally projecting tongue (154) mentioned above. Clamp arm (3182) ispivotally connected to pin (3188) and integral pin feature (3186) suchthat translation of outer tube (3152) pivots clamp arm (3182) toward andaway from ultrasonic blade (3190).

As best seen in FIGS. 45A-45B, outer tube (3152) and inner tube (3170)together define a flush port (3156). A cleaning feature (3160) extendsfrom the inner diameter of inner tube (3170) toward waveguide (3192). Inbetween surgical procedures, acoustic waveguide (3192) and blade (3190)may be advanced distally such that distal seal (3192) makes contact withcleaning feature (3160). Cleaning feature (3160) is dimensioned to makecontact with acoustic waveguide (3192) when waveguide (3192) and blade(3190) are advanced distally. Cleaning feature (3160) may dislodge anyexcess surgical debris that caked onto the portion of waveguide (3192)in contact with cleaning feature (3160). Waveguide (3192) and blade(3190) may be advanced proximally back to the position shown in FIG.45A, and an operator may inject fluid into flush port (3156) to washaway any debris remaining on waveguide (3192).

FIGS. 46-47 show different geometric shapes that cleaning feature (3160)may have. FIG. 46 shows cleaning feature (3160) as a pair of nubs makingcontact with the top and bottom of waveguide (3192). Alternatively, FIG.47 shows cleaning feature (3160) as a ring encompassing waveguide(3192). Any other geometric shape may be used as would be apparent toone having ordinary skill in the art in view of the teachings herein.

III. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

A surgical instrument comprising: (a) a shaft assembly defining alongitudinal axis, wherein the shaft assembly comprises: (i) a firsttube having an first inner diameter and a distal end, and (ii) anacoustic waveguide having a first outer diameter, wherein the acousticwaveguide extends within the first tube, wherein the first outerdiameter of the acoustic waveguide and the first inner diameter of thefirst tube together define a gap; (b) an ultrasonic blade coupled withthe acoustic waveguide, wherein the ultrasonic blade extends distallyfrom the distal end of the first tube, wherein the acoustic waveguide isconfigured to communicate ultrasonic energy to the ultrasonic blade; and(c) a cleaning device configured to actuate within the gap to therebyclean at least a portion of the shaft assembly and/or at least a portionof the ultrasonic blade.

Example 2

The surgical instrument of Example 1, wherein the cleaning devicecomprises a brush assembly configured to actuate within the gap.

Example 3

The surgical instrument of Example 2, wherein the brush assembly furthercomprises a wire and a brush.

Example 4

The surgical instrument of Example 3, wherein the wire and the brushextend along a helical path.

Example 5

The surgical instrument of Example 4, wherein the helical path defines asecond inner diameter and a second outer diameter, wherein the secondinner diameter is configured to contact the first outer diameter,wherein the second outer diameter is configured to contact the firstinner diameter.

Example 6

The surgical instrument of any one of Examples 1 through 5, wherein thecleaning device further defines a lumen configured to deliver fluidwithin the first tube.

Example 7

The surgical instrument of any one of Examples 1 through 6, wherein theultrasonic blade has a curved longitudinal profile.

Example 8

The surgical instrument of any one of Examples 1 through 7, wherein thesurgical instrument further comprises a body, wherein the cleaningdevice is housed within the body, wherein the cleaning device isconfigured to be removed from the body in order to actuate within thegap.

Example 9

The surgical instrument of any one of Examples 1 through 8, wherein thecleaning device comprises a hollow shaft, wherein the hollow shaft isconfigured to actuate within the gap.

Example 10

The surgical instrument of Example 9, wherein the cleaning devicefurther comprises a brush, wherein the brush wraps around the hollowshaft, wherein the brush is configured to contact the first innerdiameter and the first outer diameter when the hollow shaft actuateswithin the gap.

Example 11

The surgical instrument of Example 10, wherein the hollow shaft furthercomprises a plurality of recesses.

Example 12

The surgical instrument of Example 11, wherein the cleaning devicefurther comprises a retention sleeve configured to retain the brushrelative to the hollow shaft.

Example 13

The surgical instrument of any one of Examples 11 through 12, whereinthe brush at least partially extends through the plurality of recesses.

Example 14

The surgical instrument of any one of Examples 9 through 13, wherein thecleaning device further comprises a plurality of brushes traveling alongthe length of the hollow shaft on an exterior of the hollow shaft and aninterior of the hollow shaft.

Example 15

The surgical instrument of any one of Examples 10 through 14, whereinthe hollow shaft further comprise a radial array of protrusions, whereinthe brush wraps around at least one protrusion of the radial array ofprotrusions.

Example 16

The surgical instrument of any one of Examples 9 through 15, wherein thehollow shaft is layered in an abrasive material.

Example 17

The surgical instrument of any one of Examples 9 through 16, wherein thehollow shaft comprises a scraper edge configured to wrap around thefirst outer diameter when the cleaning device actuates within the gap.

Example 18

A surgical instrument comprising: (a) a shaft assembly defining alongitudinal axis, wherein the shaft assembly comprises: (i) a firsttube having an first inner diameter and distal end, wherein the firsttube defines a slot, and (ii) an acoustic waveguide having a first outerdiameter, wherein the acoustic waveguide extends within the first tube,wherein the first outer diameter of the acoustic waveguide and the firstinner diameter of the first tube together define a gap; (b) anultrasonic blade coupled with the acoustic waveguide, wherein theultrasonic blade extends distally from the distal end of the first tube,wherein the acoustic waveguide is configured to communicate ultrasonicenergy to the ultrasonic blade; and (c) a cleaning device configured toactuate within the gap and along the slot to thereby clean at least aportion of the shaft assembly and/or at least a portion of theultrasonic blade.

Example 19

The surgical instrument of Example 18, wherein the slot forms an arcedpath, wherein the cleaning device is configure to actuate within the gapby rotating within the slot.

Example 20

A surgical instrument comprising: (a) a shaft assembly defining alongitudinal axis, wherein the shaft assembly comprises: (i) a firsttube having an first inner diameter and a distal end, and (ii) anacoustic waveguide having a first outer diameter, wherein the acousticwaveguide extends within the first tube, wherein the first outerdiameter of the acoustic waveguide and the first inner diameter of thefirst tube define a gap; (b) an end effector comprising: (i) anultrasonic blade coupled with the acoustic waveguide, wherein theultrasonic blade extends distally from the distal end of the first tube,wherein the acoustic waveguide is configured to communicate ultrasonicenergy to the ultrasonic blade, and (ii) a clamp arm configured to pivottoward and away from the ultrasonic blade; and (c) a cleaning deviceconfigured to actuate within the gap in response to the clamp armpivoting toward and away from the ultrasonic blade to thereby clean atleast a portion of the shaft assembly and/or at least a portion of theultrasonic blade.

IV. Miscellaneous

It should be understood that any of the versions of instrumentsdescribed herein may include various other features in addition to or inlieu of those described above. By way of example only, any of theinstruments described herein may also include one or more of the variousfeatures disclosed in any of the various references that areincorporated by reference herein. It should also be understood that theteachings herein may be readily applied to any of the instrumentsdescribed in any of the other references cited herein, such that theteachings herein may be readily combined with the teachings of any ofthe references cited herein in numerous ways. Other types of instrumentsinto which the teachings herein may be incorporated will be apparent tothose of ordinary skill in the art.

It should also be understood that any ranges of values referred toherein should be read to include the upper and lower boundaries of suchranges. For instance, a range expressed as ranging “betweenapproximately 1.0 inches and approximately 1.5 inches” should be read toinclude approximately 1.0 inches and approximately 1.5 inches, inaddition to including the values between those upper and lowerboundaries.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool withUltrasound Cauterizing and Cutting Instrument,” published Aug. 31, 2004,the disclosure of which is incorporated by reference herein.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by an operatorimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. A surgical instrument comprising: (a) a shaft assemblydefining a longitudinal axis, wherein the shaft assembly comprises: (i)a first tube having an first inner diameter and a distal end, and (ii)an acoustic waveguide having a first outer diameter, wherein theacoustic waveguide extends within the first tube, wherein the firstouter diameter of the acoustic waveguide and the first inner diameter ofthe first tube together define a gap; (b) an ultrasonic blade coupledwith the acoustic waveguide, wherein the ultrasonic blade extendsdistally from the distal end of the first tube, wherein the acousticwaveguide is configured to communicate ultrasonic energy to theultrasonic blade; and (c) a cleaning device configured to actuate withinthe gap to thereby clean at least a portion of the shaft assembly and/orat least a portion of the ultrasonic blade, wherein the cleaning devicecomprises a hollow shaft defining a lumen, wherein the lumen isdimensioned to receive the acoustic waveguide such that the hollow shaftis configured to actuate within the gap.
 2. The surgical instrument ofclaim 1, wherein the cleaning device comprises a brush assemblyconfigured to actuate within the gap.
 3. The surgical instrument ofclaim 2, wherein the brush assembly further comprises a wire and abrush.
 4. The surgical instrument of claim 3, wherein the wire and thebrush extend along a helical path.
 5. The surgical instrument of claim4, wherein the helical path defines a second inner diameter and a secondouter diameter, wherein the second inner diameter is configured tocontact the first outer diameter, wherein the second outer diameter isconfigured to contact the first inner diameter.
 6. The surgicalinstrument of claim 1, wherein the lumen is configured to deliver fluidwithin the first tube.
 7. The surgical instrument of claim 1, whereinthe ultrasonic blade has a curved longitudinal profile.
 8. The surgicalinstrument of claim 1, wherein the surgical instrument further comprisesa body, wherein the cleaning device is housed within the body, whereinthe cleaning device is configured to be removed from the body in orderto actuate within the gap.
 9. The surgical instrument of claim 1,wherein the cleaning device further comprises a brush, wherein the brushwraps around the hollow shaft, wherein the brush is configured tocontact the first inner diameter and the first outer diameter when thehollow shaft actuates within the gap.
 10. A surgical instrumentcomprising: (a) a body; (b) a shaft assembly extending distally from thebody, wherein the shaft assembly defines a longitudinal axis, whereinthe shaft assembly comprises: (i) a first tube having a first innerdiameter and a distal end, and (ii) an acoustic waveguide having a firstouter diameter, wherein the acoustic waveguide extends within the firsttube, wherein the first outer diameter of the acoustic waveguide and thefirst inner diameter of the first tube together define a gap; (b) anultrasonic blade coupled with the acoustic waveguide, wherein theultrasonic blade extends distally from the distal end of the first tube,wherein the acoustic waveguide is configured to communicate ultrasonicenergy to the ultrasonic blade; and (c) a cleaning device configured toactuate within the gap to thereby clean at least a portion of the shaftassembly and/or at least a portion of the ultrasonic blade, wherein thecleaning device is housed within the body, wherein the cleaning deviceis configured to be removed from the body in order to actuate within thegap.
 11. The surgical instrument of claim 10, wherein the body furthercomprises a rotating knob, wherein the cleaning device is configured tobe removed from the rotating knob in order to actuate within the gap.12. The surgical instrument of claim 11, wherein the rotating knobdefines a recess configured to house the cleaning device.
 13. Thesurgical instrument of claim 10, wherein the cleaning device furthercomprise a helical wire and a brush body, wherein the brush bodysurrounds the helical wire.
 14. A surgical instrument comprising: (a) ashaft assembly defining a longitudinal axis, wherein the shaft assemblycomprises: (i) a first tube having an first inner diameter and a distalend, and (ii) an acoustic waveguide having a first outer diameter,wherein the acoustic waveguide extends within the first tube, whereinthe first outer diameter of the acoustic waveguide and the first innerdiameter of the first tube together define a gap; (b) an ultrasonicblade coupled with the acoustic waveguide, wherein the ultrasonic bladeextends distally from the distal end of the first tube, wherein theacoustic waveguide is configured to communicate ultrasonic energy to theultrasonic blade; and (c) a cleaning device configured to actuate withinthe gap to thereby clean at least a portion of the shaft assembly and/orat least a portion of the ultrasonic blade, wherein the cleaning devicecomprises a brush assembly comprising: (i) a wire, and (ii) a brush,wherein the wire and the brush extend along a helical path, wherein thehelical path defines a second inner diameter and a second outerdiameter, wherein the second inner diameter is configured to contact thefirst outer diameter, wherein the second outer diameter is configured tocontact the first inner diameter.
 15. The surgical instrument of claim14, wherein the cleaning device further comprises a handle.
 16. Thesurgical instrument of claim 15, wherein the brush assembly is connectedto the handle via an interference fit.
 17. The surgical instrument ofclaim 15, wherein the cleaning device comprises a removable cap.
 18. Thesurgical instrument of claim 14, wherein the cleaning device comprises aluer fitting.